HDX Static Hydraulic Universal Testing System - System ...

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Industrial Products Group

Model HDX Static HydraulicUniversal Testing System

System Concepts ManualM47-17032-EN Revision A

The difference is measurable ®

Electromagnetic Compatibility

Where applicable, this equipment is designed to comply with International Electromagnetic Compatibility (EMC) standards.

To ensure reproduction of this EMC performance, connect this equipment to a low impedance ground connection. Typical suitable connections are a ground spike or the steel frame of a building.

Proprietary Rights Notice

This document and the information that it contains are the property of Illinois Tool Works Inc. (ITW). Rights to duplicate or otherwise copy this document and rights to disclose the document and the information that it contains to others and the right to use the information contained therein may be acquired only by written permission signed by a duly authorized officer of ITW.

Trademarks

Instron® is a registered trademark of Illinois Tool Works Inc. (ITW). Other names, logos, icons and marks identifying Instron products and services referenced herein are trademarks of ITW and may not be used without the prior written permission of ITW.

Other product and company names listed are trademarks or trade names of their respective companies.

Original Instructions

Copyright © 2016 Illinois Tool Works Inc. All rights reserved. All of the specifications shown in this document are subject to change without notice.

Corporate Headquarters

Instron825 University Avenue

Norwood, MA 02062-2643United States of America

European Headquarters

InstronCoronation Road

High Wycombe, Bucks HP12 3SYUnited Kingdom

Industrial Products Group

Instron 900 Liberty Street

Grove City, PA 16127 United States of America

Preliminary Pages

General Safety Precautions

Materials testing systems are potentially hazardous.

Materials testing involves inherent hazards from high forces, rapid motions, and stored energy. You must be aware of all moving and operating components in the testing system that are potentially hazardous, particularly force actuators or a moving crosshead.

Carefully read all relevant manuals and observe all Warnings and Cautions. The term Warning is used where a hazard may lead to injury or death. The term Caution is used where a hazard may lead to damage to equipment or to loss of data.

Instron products, to the best of its knowledge, comply with various national and international safety standards, in as much as they apply to materials and structural testing. We certify that our products comply with all relevant EU directives (CE mark).

Because of the wide range of applications with which our instruments are used, and over which we have no control, additional protection devices and operating procedures may be necessary due to specific accident prevention regulations, safety regulations, further EEA directives or locally valid regulations. The extent of our delivery regarding protective devices is defined in your initial sales quotation. We are thus free of liability in this respect.

At your request, we will gladly provide advice and quotations for additional safety devices such as protective shielding, warning signs or methods of restricting access to the equipment.

The following pages detail various general warnings that you must heed at all times while using materials testing equipment. You will find more specific Warnings and Cautions in the text whenever a potential hazard exists.

Your best safety precautions are to gain a thorough understanding of the equipment by reading your instruction manuals and to always use good judgment.

It is our strong recommendation that you should carry out your own product safety risk assessment.

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Preliminary Pages

Warnings

Hazard - Press the Emergency Stop button whenever you consider that an unsafe condition exists.

The Emergency Stop button removes hydraulic power or electrical drive from the testing system and brings the hazardous elements of the system to a stop as quickly as possible. It does not isolate the system from electrical power, other means are provided to disconnect the electrical supply. Whenever you consider that safety may be compromised, stop the test using the Emergency Stop button. Investigate and resolve the situation that caused the use of the Emergency Stop button before you reset it.

Flying Debris Hazard - Make sure that test specimens are installed correctly in grips or fixtures in order to eliminate stresses that can cause breakage of grip jaws or fixture components.

Incorrect installation of test specimens creates stresses in grip jaws or fixture components that can result in breakage of these components. The high energies involved can cause the broken parts to be projected forcefully some distance from the test area. Install specimens in the center of the grip jaws in line with the load path. Insert specimens into the jaws by at least the amount recommended in your grip documentation. This amount can vary between 66% to 100% insertion depth; refer to supplied instructions for your specific grips. Use any centering and alignment devices provided.

Hazard - Protect electrical cables from damage and inadvertent disconnection.

The loss of controlling and feedback signals that can result from a disconnected or damaged cable causes an open loop condition that may drive the actuator or crosshead rapidly to its extremes of motion. Protect all electrical cables, particularly transducer cables, from damage. Never route cables across the floor without protection, nor suspend cables overhead under excessive strain. Use padding to avoid chafing where cables are routed around corners or through wall openings.

High/Low Temperature Hazard - Wear protective clothing when handling equipment at extremes of temperature.

Materials testing is often carried out at non-ambient temperatures using ovens, furnaces or cryogenic chambers. Extreme temperature means an operating temperature exceeding 60 °C (140 °F) or below 0 °C (32 °F). You must use protective clothing, such as gloves, when handling equipment at these temperatures. Display a warning notice concerning low or high temperature operation whenever temperature control equipment is in use. You should note that the hazard from extreme temperature can extend beyond the immediate area of the test.

4 M47-17032-EN

Preliminary Pages

Crush Hazard - Take care when installing or removing a specimen, assembly, structure, or load string component.

Installation or removal of a specimen, assembly, structure, or load string component involves working inside the hazard area between the grips or fixtures. When working in this area, ensure that other personnel cannot operate any of the system controls. Keep clear of the jaws of a grip or fixture at all times. Keep clear of the hazard area between the grips or fixtures during actuator or crosshead movement. Ensure that all actuator or crosshead movements necessary for installation or removal are slow and, where possible, at a low force setting.

Hazard - Do not place a testing system off-line from computer control without first ensuring that no actuator or crosshead movement will occur upon transfer to manual control.

The actuator or crosshead will immediately respond to manual control settings when the system is placed off-line from computer control. Before transferring to manual control, make sure that the control settings are such that unexpected actuator or crosshead movement cannot occur.

Robotic Motion Hazard - Keep clear of the operating envelope of a robotic device unless the device is de-activated.

The robot in an automated testing system presents a hazard because its movements are hard to predict. The robot can go instantly from a waiting state to high speed operation in several axes of motion. During system operation, keep away from the operating envelope of the robot. De-activate the robot before entering the envelope for any purpose, such as reloading the specimen magazine.

Hazard - Set the appropriate limits before performing loop tuning or running waveforms or tests.

Operational limits are included within your testing system to suspend motion or shut off the system when upper and/or lower bounds of actuator or crosshead travel, or force or strain, are reached during testing. Correct setting of operational limits by the operator, prior to testing, will reduce the risk of damage to test article and system and associated hazard to the operator.

Electrical Hazard - Disconnect the electrical power supply before removing the covers to electrical equipment.

Disconnect equipment from the electrical power supply before removing any electrical safety covers or replacing fuses. Do not reconnect the power source while the covers are removed. Refit covers as soon as possible.

Warnings



Preliminary Pages

Rotating Machinery Hazard - Disconnect power supplies before removing the covers to rotating machinery.

Disconnect equipment from all power supplies before removing any cover which gives access to rotating machinery. Do not reconnect any power supply while the covers are removed unless you are specifically instructed to do so in the manual. If the equipment needs to be operated to perform maintenance tasks with the covers removed, ensure that all loose clothing, long hair, etc. is tied back. Refit covers as soon as possible.

Hazard - Shut down the hydraulic power supply and discharge hydraulic pressure before disconnection of any hydraulic fluid coupling.

Do not disconnect any hydraulic coupling without first shutting down the hydraulic power supply and discharging stored pressure to zero. Tie down or otherwise secure all pressurized hoses to prevent movement during system operation and to prevent the hose from whipping about in the event of a rupture.

Hazard - Shut off the supply of compressed gas and discharge residual gas pressure before you disconnect any compressed gas coupling.

Do not release gas connections without first disconnecting the gas supply and discharging any residual pressure to zero.

Explosion Hazard - Wear eye protection and use protective shields or screens whenever any possibility exists of a hazard from the failure of a specimen, assembly or structure under test.

Wear eye protection and use protective shields or screens whenever a risk of injury to operators and observers exists from the failure of a test specimen, assembly or structure, particularly where explosive disintegration may occur. Due to the wide range of specimen materials, assemblies or structures that may be tested, any hazard resulting from the failure of a test specimen, assembly or structure is entirely the responsibility of the owner and the user of the equipment.

Hazard - Ensure components of the load string are correctly pre-loaded to minimize the risk of fatigue failure.

Dynamic systems, especially where load reversals through zero are occurring, are at risk of fatigue cracks developing if components of the load string are not correctly pre-loaded to one another. Apply the specified torque to all load string fasteners and the correct setting to wedge washers or spiral washers. Visually inspect highly stressed components such as grips and threaded adapters prior to every fatigue test for signs of wear or fatigue damage.

Warnings

6 M47-17032-EN

Preliminary Pages

Table of Contents

Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

About these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Frame configuration options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Testing accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

System identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Product support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Product documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Calibration and verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Service Agreements/Contracts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Calibration Upon Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Calibration Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Chapter 2 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Existing transducer rationalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Computer system - ethernet card availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Hydraulic interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Electrical interconnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Software and computer setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Load software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Communication setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Initial startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Recommended procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Install grip assembly components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Optional accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Chapter 3 Additional System Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Test space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Tension crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Adjustable crosshead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Grip assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Manual grip actuation - G1-style crossheads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Hydraulic grip actuation - G7-style crossheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Limit switch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36



Preliminary Pages

Load measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Position measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Optional accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Controls and electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

59 Series control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Computer system and controlling software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Electrical panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Hydraulic power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Pump and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Manifold assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Servo manifold assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Crosshead motor manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Frame manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Hydraulic grips manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Speed control manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Pressure settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Oil cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Chapter 4 Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Replacement of fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Inspect/replace 59 Series power entry module fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Recommended procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Replacement or repair of load cells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8 M47-17032-EN

Chapter 1Introduction

• About these instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

• System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

• Product support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

• Product documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

• Calibration and verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

About these instructionsThese instructions provide additional information beyond what is necessary to operate the various models of the HDX testing systems. These instructions are intended for a laboratory or facilities supervisor, or Instron service personnel.

These instructions assume the following:

• You are an operator familiar with the operation of materials testing systems in general.

• Your system has been installed in its final location according to the requirements outlined in the system’s Pre-Installation Manual.

• Your system consists of a frame, a hydraulic power supply, a control unit, a computer system with an Instron materials testing software package, and any testing accessories necessary to secure the specimen in the test space.

• Software test methods that are appropriate for your testing requirements are available.

These instructions do not include the development of test methods within the materials testing software. This is covered in more advanced training that can be provided by Instron Service and Training departments.

Throughout your documentation are NOTE, CAUTION and WARNING statements that alert you to important information. They appear as follows:

CautionCautions alert the user to situations that may cause equipment damage.

Warning

Notes provide further clarification on particular issues.

Warnings alert the user to situations that may cause serious personal injury or death.

9

Chapter 1: Introduction

System overview

Purpose

Warning

The Instron Model HDX Static Hydraulic Universal Testing Systems are available in a variety of capacities. They have been developed for high-capacity testing to provide the forces necessary for static tension, compression, bend and shear testing. They are suited for tests on specimen samples such as bar, rebar, plate, tube, pipe, sheet, wire, and concrete. These frames feature two test spaces so that users can quickly change between tension and compression testing without having to remove heavy fixtures. This flexible design helps to ensure safety, reduce operator fatigue and improve productivity.

System componentsModel HDX systems consist of:

• Frame

• Hydraulic Power Supply (HPS)

• 59 Series control unit and other system controls and electronics

• Instron approved computer system with Instron materials testing software

Figure 1 identifies the system components and various frame configurations (see “Frame configuration options” on page 12).

If the equipment is used in a manner not specified by Instron, the protection provided by the equipment may be impaired. Injury to personnel or damage to the system may result. Be sure to read and understand the material presented in these instructions and in any other accompanying instructions.

10 M47-17032-EN

About these instructions

Figure 1. HDX testing systems - various configurations shown.

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Frame configuration optionsFrames can be configured with a variety of options. These options include:

• Crosshead variations:

• G1-style crossheads - Closed-front crossheads with manually operated grip assemblies for tension testing

• G7-style crossheads - Open-front crossheads with hydraulically operated grip assemblies for tension testing

• Test opening variations:

• B - Basic test openings

• C - Increase tension and compression test spaces by: 508 mm (20 in) for 1000HDX frames, 610 mm (24 in) for 1500HDX frames

The configuration options selected for your frame are identified in the complete model number of the frame. The complete model number is defined as:

{Capacity (in kN)}{Model family}-{Crosshead style option}{Test opening option}

Some examples would be:

1000HDX-G1B, 1000HDX-G7C, 1500HDX-G1B, 1500HDX-G7B

It is very important to be aware of and understand the configuration of your frame as you perform various operations and procedures so that they can be performed correctly - the complete model number (in whole or in part) is used throughout this manual to identify specifications and procedures appropriate for your frame configuration. Knowing the complete model number of your frame is critical. To determine the complete model number (and thus configuration) of your frame, refer to one of the following:

• The frame serial tag (see “System identification” on page 12)

• The Instron quote

Testing accessoriesTesting accessories are purchased separately from the frame. Testing accessories either provide a means to secure the specimen in the test space or provide additional functionality to the frame. Instructions on the installation, use and maintenance of Instron testing accessories are provided separately with each testing accessory. A variety of testing accessories are available. Contact your Instron Sales Representative for more information.

System identificationYour system has been given a unique serial number for system identification. This serial number can be found on the serial tag located on the rear of the frame (i.e. the frame serial tag). A duplicate serial tag can also be found on the rear of the HPS console.

In addition, the following components have also been given a unique serial number:

• 59 Series control unit - This serial number can be found on the rear of the control unit.

• HPS - This serial number can be found on the rear of the HPS (rear cover of console must be removed).

The frame serial tag includes other important system information, including information on your frame’s configuration. Frame configuration information can also be found on your Instron quote. Refer to “Frame configuration options” on page 12 for explanation of frame configuration.

12 M47-17032-EN

Product documentation

Product supportInstron provides documentation, including manuals and online help, that can answer many of the questions you may have. It is recommended that you review the documentation sent with the system you purchased for possible solutions to your questions.

If you cannot find answers in these sources, contact Instron’s Services department directly. A list of Instron offices is available on our website at www.instron.com. You may email your questions to [email protected] (if your system is still in warranty, please include “IPG Warranty” in the subject line). In the US and Canada, you can call directly at 1-800-473-7838.

Product documentationInstron offers a comprehensive range of documentation to help you get the most out of your Instron products. Depending on what you have purchased, your documentation may include some or all of the following:

We welcome your feedback on any aspect of the product documentation. Please email [email protected] with your comments.

Pre-Installation Manual Information about preparing your site for installation of the system, receiving the system, and lifting and handling of the system.

Operating Instructions How to use your system components and controls, and other frequently performed operating tasks.

System Concepts Additional information about your system.

Online Help Software products come complete with context sensitive help, which provides detailed information on how to use all software features.

Accessory Equipment Reference

How to set up and use any accessories you have purchased, for example grips, fixtures, extensometers, transducers, hydraulic power units, non-standard actuators, and environmental chambers.




Calibration and verificationBefore shipment from the factory, your system is calibrated and tested to ensure that it meets its performance specifications. The factory calibration is traceable to national standards, but is not a full calibration meeting all the requirements of the relevant ISO and ASTM standards. ISO 7500-1 and ASTM E4 both state that a calibration must be performed after installation for it to meet their standard. This helps ensure that any changes in calibration during shipment are corrected before any test data is taken. These standards also recommend that verifications are performed annually or whenever the system is moved.

Service Agreements/ContractsIn many countries and territories Instron Service offers a variety of service agreements and contracts to cover such things as annual verification, maintenance, repair coverage, and hotline support for your system. Contact your local Instron office for details on a service agreement or contract that best matches your needs. A listing of Instron offices can be found on the Instron web site at www.instron.com.

Calibration Upon InstallationASTM, ISO, and EN standards require the system be calibrated when it is installed or when it is moved or relocated. Instron calibrates the system at the factory, and provides a record of readings for the load cell. This frame may be verified on-site to ASTM E-4, BS 1610, DIN 51221, ISO 7500/1, EN 10002-2, JIS B7721, JIS B773 or AFNOR A03-501 standards. The factory calibration is not a complete verification to any current version of any of the above standards. Installation and Basic Software training are included with the purchase of your system. Verification services are available at a reduced rate if performed as part of the installation, but must be purchased separately. Contact your local Instron office for more information about our on-site verification services. Refer to “Calibration Services” below for more information about Instron’s calibration services.

Calibration ServicesIn addition to the initial calibration service available at installation, Instron recommends verifying your transducers on a regular schedule (at least annually) to ensure that your system operates properly and meets ISO and ASTM standards.

Instron’s Professional Services Department provides a wide range of calibration services including:

• Force

• Strain

• Torsion

• Temperature

• Crosshead displacement

• Crosshead speed

Contact your local Instron office for more information about our on-site verification services. Refer to “Product support” on page 13 for Instron’s contact information.

14 M47-17032-EN

Chapter 2Installation Notes

• Existing transducer rationalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

• Computer system - ethernet card availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

• Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

• Software and computer setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

• Initial startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

• Install grip assembly components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

• Optional accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Existing transducer rationalizationIf you will be using existing extensometers or low-range load cells with your new system, the additional transducers may need to be rationalized in order to work correctly with the new system. Contact your local Instron office for more information about our on-site rationalization services. Refer to “Product support” on page 13 for Instron’s contact information.

If factory rationalization was purchased, these transducers will be requested 2-3 weeks prior to shipment of the system in order to integrate them. Some instruments can be rationalized separately from the shipment of the system, if necessary, to maintain your testing commitments. Contact your local Instron office for more information.

Field rationalization of some transducers is also available, though it is a more expensive option. This is often preferable because it will allow using the instrument on your existing system until the new system is installed.

Computer system - ethernet card availabilityThe system uses an Ethernet Frame Interface (EFI) to provide communication between the 59 Series control unit and the computer system. The EFI is housed inside the 59 Series control unit. Use of this EFI requires an Ethernet card in the computer system:

• If a new computer system is purchased as part of the testing system and is supplied from the factory, then the computer includes two Ethernet ports - one for use with the EFI and one for normal network use. The computer system is ready for use and no preparation is required.

• If the computer system is customer supplied, then it must include at least one Ethernet port for use with the EFI and, if the computer will be connected to a network, then it must include a second Ethernet port. Be sure the Ethernet cards/ports are installed in the computer.

The second Ethernet port must be used exclusively for communications between the computer and the 59 Series control unit. If you want to connect the computer to a network, you will need to use the first (Motherboard) Ethernet port or install an additional Ethernet card. Contact your IT department or Instron service for assistance if required.

15

Chapter 2: Installation Notes

InterconnectionsThe following interconnection information is provided for reference. It is not intended to be a complete step-by-step installation procedure, but it does provide a general guideline of what and how system components should be interconnected. Depending on the components supplied with your system, all the interconnections listed may not be necessary for your system. This list may also be used as a reference if it becomes necessary to move the system or frame at a later date.

Hydraulic interconnectionsIt is necessary to connect the supplied hydraulic hoses between the HPS and the frame. Multiple connections may be necessary depending on system configuration or options purchased. Table 1 provides the connection information.

Table 1. Hydraulic connections between frame and HPS.

Make Connections For: Hose DescriptionConnection on Frame

Manifold (See Figure 2)

Connection on HPS Panel

(See Figure 3)

All frames

Hydraulic cylinder pressure hose 2 2

Hydraulic cylinder return hose 6 6

Pilot pressure hose 3 3

Auxiliary pressure hose 1 1

Figure 2. Frame manifold connections - located on rear of frame base.

Frame manifold Hydraulic grips manifold(frames with G7-style crossheads only)

16 M47-17032-EN

Interconnections

Figure 3. HPS connection panels.

Electric connectionsA through F

Hydraulic connections1 through 6

(typical connections shown, not all connections

may be used by your system)




Electrical interconnectionsBefore making electrical interconnections, all system components (including the 59 Series control unit, pendant station and computer system) should be unpacked and in place at the installation site. Also, the computer system components can and should be interconnected as outlined by the computer manufacturer. Check the electrical nameplate of each computer component and connect to an appropriate power source.

Refer to Table 2, Figure 3 and Figure 4 as you step through the interconnection process.

Table 2. Electrical connections required.

Cable Connect From Connect To

Ethernet crossover cable, male RJ45 Auxiliary Ethernet connection on rear of computer

Ethernet connection on front of 59 Series control unit (see Figure 4)

User control panel cable, female 7-pin User control panel (typically hardwired)

Connection N on rear of 59 Series control unit

HPS control box cable, male 15-pin HPS control box (typically hardwired)

Connection M on rear of 59 Series control unit

HPS emergency stop cable, male 6-pin HPS control box (typically hardwired)

Connection F on HPS connection panel

HPS cable, male 14-pin Connection A on rear of 59 Series control unit

Connection A on HPS connection panel

Frame cable, male 10-pin Junction box on frame (typically hardwired)

Connection R on rear of 59 Series control unit

Load transducer cable, male 25-pin LOAD connection on front of 59 Series control unit

Load transducer on frame

Position cable, male 9-pin Connection H on rear of 59 Series control unit

Position encoder on frame

For systems that include an optional enclosure Interlock cable

Junction box on frame - usually needs to be hardwired

Enclosure interlocks - typically routed along inside of enclosure to its exit point

Ground cable Ground stud on rear of 59 Series control unit

Ground stud on frame

Power cable for 59 Series control unit Power module on rear of 59 Series control unit

Appropriate outlet or power strip

HPS main power cable Connection D on HPS connection panel

Customer power supply of appropriate rating

For systems that include the optional Versachannel or MultichannelCoaxial cable, male BNC

SYNC (BNC) connection on front of 59 Series control unit (see Figure 4)

BNC connection on the Versachannel or Multichannel box

For systems that include the optional Expansion Channel Module68-Way mini-D cable

Expansion port on front of 59 Series control unit (see Figure 4)

X1 connection on rear of Expansion Channel Module box

18 M47-17032-EN

Interconnections

Figure 4. 59 Series control unit connection panels.

Front Panel Rear Panel

Expansion port(optional)




Software and computer setupWhen a new computer system is purchased as part of the testing system and is supplied from the factory, or if a customer supplied computer was returned to the factory for integration with the system, then the computer system and controlling software were set up at the factory before shipment. If either of these is the case with your system, this portion of the installation procedures is not required, continue system installation with “Initial startup” on page 25.

If the computer system is supplied such that it will be integrated into the system at the customer’s facility, then it is necessary to load and set up the controlling software and to set up the computer system for communication.

Load softwareFollow procedures provided with the Materials Testing Software CD.

Communication setupRecommended procedure:

1. Turn the power switch on the rear of the 59 Series control unit to ON ( | ).

2. Turn on the computer and perform the following to set up the network:

a. In Windows, choose the network connections tool per your operating system:

i. In Windows XP it is found under Start/Control Panel. Select the network card associated with the EFI; right click on it and select Properties. The Properties window will open. Select “Internet Protocol (TCP/IP)” and click on Properties (Figure 5).

ii. In Windows 7 it is found under Start/Control Panel/Network and Internet/Network and Sharing Center. Click the Local Area Connection link for the network card associated with the EFI. The Properties window will open. Select “Internet Protocol Version 4 (TCP/IPv4)” and click on Properties (Figure 5).

b. On the Internet Protocol (TCP/IP) Properties window (see Figure 6) you must manually assign an IP address to the NIC card installed in the PC. Select the “Use the following IP address” radio button. Set the IP address to 169.254.1.2. The Subnet mask should populate with 255.255.255.0; if it does not, manually type it into the Subnet mask field. The Default gateway field can remain blank.

c. Click OK to exit the window.

3. Check that the lights on the front of the 59 Series control unit are illuminated as follows:

• T indicator of the SERVICE display is green

• A indicator of the SERVICE display is blinking red

If the SERVICE display flashes the letter “F” during startup, it indicates that an error has occurred. Refer to “Troubleshooting” on page 46 for more information.

20 M47-17032-EN

Interconnections

Figure 5. Local area connection properties.

Figure 6. Internet protocol properties.

Windows XP operating system Windows 7 operating system




4. Check that the lights on the user control panel are illuminated as follows:

• POWER is green

• FRAME STANDBY is red

• TEST STOPPED is red

5. Set up the controlling software to communicate via the Ethernet card that was previously installed. The procedure is dependent on which controlling software is used with the system, Partner or Bluehill. Perform the procedure for your software:

a. For systems with Partner software, perform the following:

i. Start Partner.

ii. From the Home screen, select Tools in the menu. (Ensure no procedures are open.)

iii. Select Configure from the drop-down menu.

iv. Select Controller to view the controller setup window.

v. On the General tab, verify the correct controller is selected (Figure 7).

vi. Select Ethernet as the Interface type (Figure 8); a third box appears for the MAC address.

vii. In addition to an IP address, the EFI uses a unique MAC address. Click the Find button next to the MAC address field; the software will search for the device, get the MAC address and populate the field. Alternately, you can enter the MAC address manually. The MAC address can be found on the label affixed to the front of the 59-Series control unit (usually below the Ethernet connection). The MAC address is case sensitive. The first six digits (00-90-C2) indicate that the EFI is an Instron device. The last six digits are unique to that EFI to ensure that Partner only communicates with that specific EFI (Figure 9).

viii. Click OK to exit the window.

ix. Exit Partner and then restart Partner for the changes to take effect.

Figure 7. Partner controller type selection.

22 M47-17032-EN

Interconnections

b. For systems with Bluehill software, perform the following:

i. Start Bluehill.

ii. Select the Admin button. (Ensure no methods are open.)

iii. On the Admin page, select Configuration.

Figure 8. Partner interface type selection.

Figure 9. Partner MAC address entry.




iv. Select Frame in the navigation bar (see Figure 10).

v. Select the Controller type according to the Controller Type that is indicated on the front of the Bluehill CD case.

vi. Enter the MAC address; the MAC address is case sensitive. In addition to an IP address the EFI uses a unique MAC address, which can be found on the label affixed to the front of the 59-Series control unit (usually below the ethernet connection). The first six digits (00-90-C2) indicate that the EFI is an Instron device. The last six digits are unique to that EFI to ensure that Bluehill only communicates with that specific EFI.

vii. Select the Frame model according to the Frame Selection that is indicated on the front of the Bluehill CD case.

viii. Enter the Frame serial number.

ix. Close the Admin window.

x. Exit Bluehill and then restart Bluehill for the changes to take effect.

Figure 10. Bluehill frame configuration.

24 M47-17032-EN

Interconnections

Initial startup

Recommended procedure1. Verify that the following have been completed:

• The frame is secured to the foundation (if required)

• The HPS reservoir is filled with the appropriate amount and type of oil

• The air breather assembly is installed on the fill hole of the HPS reservoir

• All system interconnect cables are installed and have secure connections

• All Operating Instructions and accompanying documentation for the system have been read and understood by the operator

• Any shipping hardware (typically painted red) has been removed from the frame

• Any crosshead blocking has been removed from the frame, including any type of wooden blocks or metal plates that secure the crossheads together

2. Locate the Operating Instructions that were supplied with the system. You will be required to refer to procedures and information that are provided in the Operating Instructions as you perform the initial startup.

3. Ensure that the test space is clear - there should be no fixtures installed in the test space. This would exclude any fixtures that were installed at the factory and remained in the test space for shipment. These fixtures can remain in the test space. Also ensure that there is no shipping hardware on the frame.

4. Perform the “System Startup” procedure provided in Chapter 3 of the Operating Instructions that were supplied with the system.

5. Check that the frame is enabled. If the frame will not enable, see “Troubleshooting” on page 46, specifically Problem No. 2 of the table. Once any problems are corrected, enable the frame.

6. Start the HPS by pressing the Pump Start button on the HPS controls; the FRAME READY indicator will illuminate. Immediately check the position of the piston within the hydraulic cylinder, the piston should be positioned so that it is neither fully retracted nor fully extended. Use the jog controls to move the piston if necessary - typically a separation of 6 mm (0.25 in) is sufficient. If the piston is in either of these conditions, the servo loop control could build up enough error to shutdown the HPS (the controlling software will display a “Position loop error”).

7. Using the JOG controls on the user control panel, stroke the hydraulic cylinder one full cycle to help bleed air out of the system and introduce hydraulic fluid into the system.

8. For systems with G7-style crossheads, use the grip controls to introduce fluid to the hydraulic grips. Open and close the grips several times.

9. It is necessary to bleed air from the hydraulic cylinder. This requires a procedure that must be performed by the Instron service engineer.

10. The system is now ready for normal operation. Before the system is operated any further, be sure to read and understand the material provided in the System Operating Instructions (supplied separately).

11. If the system will not be operated at this time, perform the “System Shutdown” procedure provided in the System Operating Instructions (supplied separately).




Install grip assembly componentsFor frames with G7-style crossheads, be sure that the grip dust covers (10, Figure 14 on page 33) are installed on the crossheads. These are typically removed for shipment and must be installed before the frame is put into operation.

For 1500HDX-G1 frames, be sure the wear plates are installed on the top of each crosshead. Each wear plate (two wear plates per crosshead) is secured by two M10 cap screws.

Optional accessoriesInstallation of accessories such as compression plates, tension rods, external grips, etc. that were purchased with your testing system are covered under separate instructions that are included with each accessory.

Some accessories are designed to be mounted temporarily in the frame, while others are designed to be mounted semi-permanently to the frame. Semi-permanent mounting means that the accessory is designed to remain mounted to, or near, the frame for most testing, regardless of whether or not the accessory is being used for a given test. The semi-permanent mounting is typically done for accessories that are large enough to make continuous installation and removal difficult and cumbersome. Accessories that are considered semi-permanently mounted would be:

• Test space enclosures

• Furnace systems

• Automatic extensometers

Semi-permanently mounted accessories are typically not installed until the system is fully operational. Typically the Instron service engineer will assist with this during installation of the system. For more detailed information on these accessories, refer to the individual instructions that are included with each accessory.

26 M47-17032-EN

Chapter 3Additional System Details

• Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

• Controls and electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

• Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

• Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Frame

Test spaceThe HDX frame is a dual test space frame capable of static tension and compression testing. The dual test space design provides both a dedicated tension test space (2, Figure 12) and a dedicated compression test space (6). To accomplish this, the frame is made up of two separate units: a loading unit and a fixed unit (see Figure 11). The loading unit applies the load to the specimen during the test. The loading unit components are: a tension crosshead, two notched columns, a compression table, and the hydraulic cylinder. The fixed unit acts as the rigid member during the test. The fixed unit components are: an adjustable crosshead, two screw columns, and the base. The fixed unit is supported in the base by a backlash eliminator assembly that provides enough force to support the static weight of the components and prevent backlash from appearing in the test load.

Applying a load to the specimen is accomplished as follows. The HPS supplies hydraulic fluid, under pressure, to the hydraulic cylinder located inside the base of the frame. This pressure forces the piston out of the hydraulic cylinder which forces the loading unit upward so that a tensile load is applied to any specimen mounted between the tension and adjustable crossheads, and a compressive load is applied to any specimen mounted between the adjustable crosshead and the compression table.

The height of both the tension test opening and the compression test opening can be adjusted between tests to accommodate different load train heights and specimen lengths. This is accomplished by adjusting the position of the tension crosshead and/or adjustable crosshead. Adjusting the position of the tension crosshead will affect only the height of the tension test opening. For more information on adjusting the position of the tension crosshead, refer to information provided in the System Operating Instructions (supplied separately). Adjusting the position of the adjustable crosshead will affect the height of both the tension test opening and compression test opening. For more information on adjusting the position of the adjustable crosshead, refer to information provided in the System Operating Instructions (supplied separately).

27

Chapter 3: Additional System Details

Figure 11. The loading unit and the fixed unit.

Loading Unit Components:

• Tension Crosshead• Notched Columns• Compression Table• Hydraulic Cylinder

Fixed Unit Components:

• Adjustable Crosshead• Screw Columns• Base

28 M47-17032-EN

Frame

Figure 12. HDX frame components.

1. Grip assembly2. Tension test space3. Notched column4. Screw column5. Adjustable crosshead controls6. Compression test space7. Tension crosshead

a. G7-styleb. G1-style

8. Lower retaining ring9. Adjustable crosshead

a. G7-styleb. G1-style

10. Compression table11. Load cell(s)12. Base13. Column cap

1

2

3

4

1

5

6

12

11

10

9b

9a

8

7b

7a 1

1

13

5




Tension crossheadThe tension crosshead is equipped with grip assemblies for tension testing. For more information on the grip assemblies, refer to information provided in the System Operating Instructions (supplied separately). When it is desired to use other tension fixtures instead of the grip assemblies to grip a specimen, external tension fixtures can be mounted to the tension crosshead with proper adapters. This is typically done by either clamping the adapter in the grip assemblies or by using the bolt pattern provided on the bottom of the crosshead to bolt the adapter (or fixture) to the crosshead. Some adapters may mount to the crosshead using the bolt pattern on the top of the crosshead. For more information on the bolt patterns, refer to information provided in the System Operating Instructions (supplied separately).

The tension crosshead (7a or 7b, Figure 12) is mounted to two notched columns (3) and is part of the loading unit. The position of the tension crosshead can be adjusted when it is necessary to change the height of the tension test opening. The crosshead can be placed at any of the available notches in the notched columns. Crosshead adjustment is only done between tests, never during a test. For procedures on adjusting the crosshead, refer to information provided in the System Operating Instructions (supplied separately).

Adjustable crossheadThe adjustable crosshead is equipped with grip assemblies for tension testing and a bumper plate on the bottom of the crosshead for attachment of compression accessories. For more information on the grip assemblies, refer to information provided in the System Operating Instructions (supplied separately).

The adjustable crosshead is mounted to two screw columns and is part of the fixed unit. The position of the adjustable crosshead can be adjusted when it is necessary to change the height of either the tension test opening or compression test opening. A hydraulic motor is used to adjust the position of the adjustable crosshead. The operator controls the hydraulic motor through a control switch on the front of the adjustable crosshead. Crosshead adjustment is only done between tests, never during a test. For more information on adjusting the position of the adjustable crosshead, refer to information provided in the System Operating Instructions (supplied separately).

Grip assembliesBoth the tension and adjustable crossheads are equipped with grip assemblies that are designed to grip specimens for tensile testing. Frames can be purchased with either manual grip actuation (G1-style crossheads) or hydraulic grip actuation (G7-style crossheads).

Manual grip actuation - G1-style crossheadsFor G1-style crossheads, the grip assemblies are actuated manually. Components of the grip assemblies are illustrated in Figure 13. The operator uses a crank handle (2) to turn a pinion that is inside the crosshead. As the pinion turns, it engages the rack teeth on the grip jaws (10). This action lifts the grip jaws into the grip pocket (4). The wedge shape of the grip pocket forces the grip jaws to close and clamp the specimen. Filler plates (9) are placed between the grip jaws and the grip pocket. For guidance on use of filler plates, refer to information provided in the System Operating Instructions (supplied separately).

A grip stop plate (5), jaw retainers (7), and a bumper plate (11) are used to retain the jaws in the grip pockets. For the tension crosshead, the grip stop plate is mounted to the top of the crosshead to keep the grip jaws in the grip pocket during specimen recoil. The jaw retainers prevent the grip jaws from falling out of the bottom of the pocket. For the adjustable crosshead, the bumper plate keeps the grip jaws from falling out of the grip pocket.

30 M47-17032-EN

Frame

Figure 13. Components of the grip assemblies for G1-style crossheads.

1. Tension crosshead2. Crank handle and pinion3. Adjustable crosshead4. Grip pocket5. Grip stop plate6. Socket head cap screw*7. Jaw retainer8. Button head cap screw*9. Filler plate10. Grip jaw11. Bumper plate

* See Operating Instructions for specifications.

View ATension Crosshead

View BAdjustable Crosshead

Exploded View Assembled View

Exploded View Assembled View

6

5

8

7

9

10

4

2

579

1

2

2

11

3

9

9

10

4

2




Hydraulic grip actuation - G7-style crossheadsFor G7-style crossheads, the grip assemblies are actuated hydraulically. Components of the grip assemblies are illustrated in Figure 14. The operator uses a grip control handset (Figure 15 on page 34) to operate a hydraulic piston that is inside the crosshead. A push plate (18) is mounted to the piston. As the piston is extended, the push plate lifts the jaw carriers (6) in the grip pocket (16). The wedge shape of the grip pocket forces the jaw carriers and grip jaws to close and clamp the specimen. The grip jaws are held to the jaw carriers by retainer setscrews (14) that are mounted in the jaw carrier. The locating boss (5a) fits into the jaw carrier recess (6a) and the retainer setscrew is tightened against the retainer button (5b). The retainer setscrews are tightened and loosened through an access hole (15) in each front guide plate (7). It is not necessary to remove the guide plate to adjust the retainer setscrew.

The oil required to operate the hydraulic piston is supplied by the HPS. The oil is directed to each crosshead by means of a hydraulic grips manifold mounted in the frame base. Once the oil reaches the crosshead, the oil is routed through a speed control manifold and to the hydraulic piston.

32 M47-17032-EN

Frame

Figure 14. Components of the grip assemblies for G7-style crossheads.

View A

View B

View C

2

1

3

4

6a6

5 5a 5b

717

16

87

56

127

15 13 14

18

9

10

11

1. Tension crosshead2. Seal plate3. Adjustable crosshead4. Bumper plate5. Grip jaw

a. Locating bossb. Retainer button

6. Jaw carriera. Jaw carrier recess

7. Guide plate (front and rear)8. Socket head cap screw

(M16 x 30 mm, quantity 6 per crosshead, torque to 270 N-m (200 ft-lbs))

9. Piston dust cover10. Grip dust cover11. Button head cap screw

(M12 x 20 mm, quantity 4 per crosshead)12. Wear plate13. Guide pin (one on each side of jaw carrier)14. Retainer setscrew (M8)15. Access hole for retainer setscrew16. Grip pocket17. Guide slot for guide pin18. Push plate and piston




Grip controls

Warning

A hand-held grip control unit (Figure 15) is supplied to control operation of the hydraulic grips. The unit is magnetically mounted to a bracket on the pendant station. The control unit can be removed from its bracket for in-hand use or can be used while mounted to the bracket.

The controls consist of two three-position rocker switches, one to operate the upper grips and one to operate the lower grips. Pressing one end of the rocker switch will actuate the jaws according to the labeling on the control unit (see Figure 15). Each switch operates as a momentary-type when it is in the Open position and as a latch-type when it is in the Close position. When a switch is placed in the Open position and then released, it automatically returns to its Neutral position and grip motion stops. When a switch is placed in the Close position, it latches in this position and closes the jaws fully. Be sure fingers or hands are not between the grip jaws when closing the jaws. The switch must remain in the Close position once the specimen is clamped and during testing. Do NOT place the switch in the Neutral position until the specimen has been removed from the grips.

The clamping speed of the grip jaws was set at the factory; refer to “Clamping Speed” on page 35. It is not recommended that the factory settings be changed; keep in mind that faster clamping speeds increase the risk of operator injury.

These grip assemblies are designed to grip specimens for testing. Therefore, an unavoidable pinching hazard exists. Make sure to read and understand all installation, removal and operating instructions before using the grip assemblies!

If a switch is in the Close position and main power is lost to the frame*, the grips will stop and hold their current position; also the switch will remain latched in the Close position but will be put into Neutral mode (i.e. will not function). When power is restored to the frame, the grips and the grip controls will remain in this hold/neutral condition until the switch is reset. The switch must be reset to restore grip function. To reset the switch, move it to the Neutral position and then operate as desired.

* For conditions that result in loss of main power to the frame, refer to the System Operating Instructions (supplied separately).

Figure 15. Hydraulic grip control handset.

Upper open

Upper close

Lower close

Lower open

34 M47-17032-EN

Frame

Clamping Speed

Warning

The speed at which the grip jaws close or open can be adjusted by the flow control valves located on the speed control manifolds. A speed control manifold is located on the rear of each crosshead. A separate flow control valve is provided for the clamping speed and unclamping speed, see Figure 16. To adjust a flow control valve:

1. Loosen locknut (see Figure 16).

2. Turn the adjustment knob as desired; increase speed by turning the knob counterclockwise and decrease speed by turning the knob clockwise.

3. Tighten the locknut.

4. Check jaw operation before inserting a specimen or performing a test.

Factory clamping speed is set to 4 mm/sec (0.16 in/sec) closure rate or less. A hazard to operators may be created if the clamping speed is adjusted faster than 4 mm/sec (0.16 in/sec).

Use caution if adjusting the clamping speed of the jaws. The jaws can be adjusted to move very quickly. Keep fingers and hands free of jaws.

Figure 16. Clamping speed adjustment - flow control valves

Lower grip open

Lower grip close

Upper grip close

Upper grip open

Adjustment Knob

Locknut




Limit switch assemblyA limit switch (2, Figure 17) is mounted to the underside of the base plate (1). The purpose of the limit switch is to protect the hydraulic cylinder from overtravel. The limit switch is actuated by a guide rod (3) that is mounted to the piston (8a). This allows the guide rod to move in conjunction with the piston. The guide rod extends through the base plate into the base (see Figure 17). As the piston reaches the limit of its travel, the stop collar (4) on the guide rod will trip the limit switch. When the limit switch is tripped, an electrical signal is sent to the 59 Series control unit and the controls shut down the HPS. The limit switch must be reset before the HPS can be restarted. To reset the limit switch, the frame must unload and allow the piston to travel away from the limit switch. The frame can only unload by gravity. To increase the unload rate, the dump valve can be manually opened by turning the system disconnect switch OFF. Once the frame is unloaded, turn the disconnect switch back ON and restart the system.

Load measurementOne or more strain gauged load cells are used to measure the force applied to the test specimen. 1000HDX frames use a single load cell and the 1500HDX frames use three load cells. The load cells (11, Figure 12 on page 29) are mounted between the compression table and piston. This mounting arrangement provides a load measuring system that is independent of the hydraulic system. This means that the force measured by the load cells is free of interference due to piston friction and hysteresis; it is a direct force measurement. For 1500HDX frames, the electrical signals from the three load cells are added together to obtain a single load reading.

Because of the dual test space design of the frame, the load cell(s) are always subjected to a compressive load - even during a tensile test. The controlling software will report the load on the specimen in the appropriate direction (tension or compression) according to the test setup.

CautionThe controlling software is equipped with overload protection for the load transducer. The overload protection should prevent damage to the load transducer during a test by shutting off the HPS when an overload condition occurs.

Figure 17. Typical limit switch and position encoder assemblies.

1. Base plate2. Limit switch3. Guide rod4. Stop collar5. Encoder string6. Position encoder7. Compression table8. Hydraulic cylinder

a. Pistonb. Cylinder body

Rear of frame with covers removed.

8a

8b

7

1

2

3

4

5

6

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Position measurementA position encoder is used to determine the position of the piston inside the hydraulic cylinder. Two position encoder resolution options are available. For specifications, refer to information provided in the System Operating Instructions (supplied separately). All encoders are digital quadrature style encoders.

HDX models use a string-type encoder (see Figure 17). The position encoder (6) is mounted in the base of the frame. The encoder string (5) is actuated by a guide rod (3) that is mounted to the piston (8). This allows the guide rod to move in conjunction with the piston. The guide rod extends through the base plate into the frame base (see Figure 17). As the piston and compression table move up and down, the guide rod also moves and actuates the encoder string which produces an electrical signal in the encoder. The electrical signal is transmitted to the 59 Series control unit. The 59 Series control unit converts the signal into the relative position of the loading unit in relation to a stationary frame member.

Optional accessoriesInstron offers a wide variety of testing accessories that can be used with the HDX frame. Some are designed to be mounted temporarily in the frame, while others are designed to be mounted semi-permanently to the frame. Semi-permanent mounting means that the accessory is designed to remain mounted to, or near, the frame for most testing, regardless of whether or not the accessory is being used for a given test. The semi-permanent mounting is typically done for accessories that are large enough to make continuous installation and removal difficult and cumbersome. This section will briefly discuss these semi-permanently mounted accessories. For more detailed information on these accessories, refer to the individual instructions that accompany each accessory.

For information on the wide variety of testing accessories that are offered by Instron, contact your local Instron Sales Representative as directed on page 13. Your Sales Representative can help you select accessories that best fit your testing needs.

• Test space enclosure: Test space enclosures surround the frame to retain specimen debris and prevent disturbance of the test in progress. Enclosures are typically floor mounted.

• Furnace system: A furnace system provides high temperature testing capability. The furnace system includes a mounting bracket for mounting to the frame; typically on the base. The mounting bracket permits rotation of the furnace so that it can be removed from the test space when not in use.

• Automatic extensometers: These extensometers provide automatic strain measurement of the specimen being tested. These extensometers are provided with a mounting bracket for mounting to the frame; typically on the base. When necessary, the mounting bracket permits rotation of the extensometer so that it can be removed from the test space when not in use.

• Tee-slot table: Tee-slot tables provide additional methods for mounting accessories to the frame table. The tee-slot table mounts directly to the frame table. Before shipment from the factory, it is mounted to the frame and typically remains installed for shipment.




Controls and electronics

59 Series control unitThe 59 Series control unit (Figure 18) is an enclosure that typically sits on the console. The unit houses control components that: receive and process data from the various system transducers; communicates with the system’s controlling software; and provides feedback to the system’s servo valve to operate the frame as set up in the controlling software. The control components consist of a digital signal processor card, transducer signal conditioning cards, a frame interface board, a 24 VDC power supply for the frame interface board, a fused power entry module, a relay board, and an optional analog outputs card (when purchased).

External connections to the control components are made on the front and rear of the unit. Connection descriptions are outlined in Table 3.

Table 3. 59 Series control unit function descriptions.

LOAD: A female 25-pin interface that connects the system’s load cell to the transducer conditioning card.

STRAIN 1:(optional)

A female 25-pin interface that connects an extensometer to an optional transducer conditioning card.

STRAIN 2:(optional)

A female 25-pin interface that connects an extensometer to an optional transducer conditioning card. (Typically only required for transverse strain or other dual extensometer setups.)

ETHERNET: A connection for communication with the computer.

I/O:(optional)

Allows connection of analog chart recorders and plotters, etc. Features 4 zero suppressed and scaled 10V outputs via BNC connectors. A 25 pin D connector provides recorder pulse drive, 4 logic line outputs and 4 logic line inputs to trigger internal and external events.

SERVICE: A connection for optional communications modem for remote diagnostics.

SERVICE Display: Provides an indication of self-tests that are performed by the controls during system startup. You should see the following general sequence: the two 7-segment LEDs count up to “21” and then back down, and then the letter “P” will flash alternately with the number “22”. This entire sequence typically takes between one and two minutes to complete. “P” indicates the all self-tests have passed. If the LEDs should flash the letter “F” at any time during the sequence, this indicates that a self-test has failed. If this occurs, you should contact your local Instron Services department as directed on page 13 for assistance in troubleshooting the failure.

When conditions are normal, the T indicator is green and the A indicator is blinking red.

HPS, A: A female 14-pin interface that connects the HPS to the control unit.

Position, H: A female 9-pin interface that connects the system’s position encoder to the control unit.

User Control Panel, N: An interface that connects the user control panel to the control unit.

HPS Controls, M: A female 15-pin interface that connects the HPS control box to the control unit.

Frame, R: A female 10-pin interface that connects various frame functions to the control unit.

Ground: A ground lug that connects the control unit to an earth ground. Typically connects to a ground lug on the frame base.

Power Entry Module: Provides a male 3-prong connection for incoming power and a power ON/OFF switch.

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Computer system and controlling softwareThe computer system is the operator communication link with the various system controls and the frame. Operators enter information and control parameters into the computer by way of the controlling software package.

The 59 Series control unit receives messages from the computer and sends the message to the testing system to perform the required operation. While testing, the controller receives data from the load and position transducers on the frame and sends the data to the computer. A frame interface board mounted inside the control unit provides signal interfacing between the controller and the system components.

Communication between the 59 Series control unit and the computer is accomplished through an Ethernet Frame Interface (EFI) that is mounted inside the 59 Series control unit.

For detailed information on the computer system, please refer to the computer manufacturer’s literature that was provided with the system. For more information on the controlling software, refer to the software’s On-line Help system or to the manual provided.

Figure 18. The 59 Series control unit.

Front Panel

Rear Panel

Expansion Port(optional)

Computer systems are typically purchased from Instron with the testing system, however they may be customer supplied. If this is the case, refer to any information provided by the computer vendor in regards to its operation, warranty, etc. Instron is not responsible for customer supplied equipment.




Electrical panel

Warning

System electronics are mounted on an electrical panel. The panel is mounted inside the electrical box on the side of the console. The electrical panel houses a motor starter for the electric motor in the HPS and an overload relay for the motor.

Disconnect the electrical power supply before removing the covers to electrical equipment.

Disconnect equipment from the electrical power supply before removing any electrical safety covers to replace fuses, inspect or clean the system. Do not reconnect the power source while the covers are removed. Refit covers as soon as possible.

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Hydraulic system

Introduction

Warning

The hydraulic system includes any component that controls or routes hydraulic fluid (oil) through the testing system. For specifications of the hydraulic oil, refer to maintenance information provided in the System Operating Instructions (supplied separately).

Hydraulic power supplyThe function of the HPS is to act as the power supply for the frame. This includes powering the hydraulic cylinder, crosshead motor, and hydraulic grip actuators (for frames with G7-style crossheads). The HPS is a variable pressure unit; it creates hydraulic pressure as required depending on system demand.

The HPS is enclosed in a console that has a desktop surface for placement of the computer system and 59 Series control unit. The components of the HPS can vary depending on the configuration of the system. In general however, major components of the HPS are: a reservoir; a pump; an electric motor; a heat exchanger; one or more manifold assemblies; and the hydraulic fluid (oil). Figure 19 identifies typical HPS components. An electrical panel mounted inside the console houses the motor starters, with overloads, for the electric motor.

When the HPS is on, the hydraulic cylinder should be positioned so that the piston is neither fully retracted nor fully extended. When the hydraulic cylinder is in either of these conditions, it is difficult for the 59 Series controls to maintain the position and the servo loop control could build up enough error to shut down the HPS.

Reservoir

CautionDO NOT start the HPS without the screen trapper or air breather assembly installed on the reservoir. Starting the HPS with the solid cap (that is used for shipping) on the reservoir instead of the air breather assembly could cause pump cavitation.

The reservoir holds the oil that is needed to operate the various hydraulic components. For approximate reservoir capacity, and information on adding oil to or changing the oil in the reservoir, refer to maintenance information provided in the System Operating Instructions (supplied separately). The reservoir is equipped with a sight gauge, air breather assembly and screen trapper.

Shut down the HPS and discharge hydraulic pressure before disconnecting any hydraulic fluid coupling.

Do not disconnect any hydraulic coupling without first shutting down the HPS and discharging stored pressure to zero. Tie down or otherwise secure all pressurized hoses to prevent movement during system operation and to prevent the hose from whipping about in the event of a rupture.




Sight gauge

The reservoir is equipped with an oil level and temperature sight gauge. The sight gauge (8, Figure 19) is visible through the rear cover of the console. The reservoir should be filled so that the oil is to the top of the sight gauge when the hydraulic cylinder is completely retracted. Filling the reservoir with the hydraulic cylinder slightly extended will cause overflowing of the reservoir when the hydraulic cylinder is retracted. The level of the oil is monitored by a level switch inside the reservoir, see “Oil temperature/level switch” on page 43. The maximum temperature of the hydraulic oil under normal operating conditions should remain below 60 deg. C (140 deg. F), and should never exceed 80 deg. C (176 deg. F). Consult factory for operating conditions that result in oil temperatures that exceed 80 deg. C (176 deg. F). Oil temperature is monitored by a temperature switch inside the reservoir, see “Oil temperature/level switch” on page 43.

Air breather assembly

An air breather assembly (6, Figure 19) is placed on the reservoir’s fill hole to allow the reservoir to breathe while preventing dirt from entering the reservoir. It can be easily removed for access to the reservoir. For maintenance of the air filter, refer to maintenance information provided in the System Operating Instructions (supplied separately).

Figure 19. Components of the HPS (V11f or 1000HDX shown).

Rear cover removed.

5

4

3

6

7

8

9

10

11b

2

11a

1

1. Heat exchanger and fan2. Motor3. System pressure gauge4. Oil filter5. Relief valve RV1

6. Air breather filter7. Fill hole8. Sight gauge9. Reservoir10. Servo manifold

11. Connection panelsa. Hydraulicb. Electric

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Screen trapper

A tightly meshed screen trapper is placed in the reservoir’s fill hole. This screen prevents larger debris from entering the reservoir when it is filled. Maintenance of the screen trapper should be done anytime oil is added to the reservoir, refer to maintenance information provided in the System Operating Instructions (supplied separately).

Oil temperature/level switch

A temperature/level switch is mounted in the reservoir that monitors the temperature and the level of the oil. The switch will trip at either an oil temperature of 70 +/-6 deg. C (158 +/-10 deg. F) or an oil level lower than 184 mm (7.25 in) from the top of the reservoir. This distance is below the bottom of the sight gauge but above the opening in the suction pipe. If the switch is tripped from either condition, the system controls will shut off the HPS. This prevents the oil temperature from exceeding the recommended maximum temperature and prevents the HPS from operating with a low oil level. The controlling software will indicate a “Motor Temp” error, no matter which condition tripped the switch. Refer to Problem No. 15 of Table 6 on page 46.

Pump and motorAn electric motor is used to operate the pump that forces oil from the reservoir, through the high pressure hydraulic hoses and into the hydraulic cylinder. As the controller directs the frame to place load on a specimen, the HPS builds pressure in the system and the piston is actuated inside the hydraulic cylinder. Some pump and motor information is listed in Table 4.

The pump is equipped with a flow control adjustment that controls the system idle pressure. Idle pressure is the pressure of the HPS when it is operating under no load conditions (i.e. when the frame is not being adjusted or performing a test). This flow control adjustment is set at the factory and should not require further adjustment. Any adjustments should only be made by an Instron service engineer.

For pump and motor maintenance, refer to the separately supplied manufacturer’s information.

Manifold assembliesThe function of any manifold is to control and route the hydraulic oil as needed to various system components. The following manifold assemblies may be present on this system (dependent on frame configuration):

• Servo manifold assembly

• Crosshead motor manifold

• Hydraulic grips manifold

• Speed control manifolds

Table 4. HPS information.

HPS Catalog Number and Model

Required Flow at Maximum Testing Speed Idle Pressure

System Relief Pressure

Motor Power

1000HDX-D22, V11f 6.25 Lpm (1.65 gpm) 21 bar (300 psi) 186 bar (2700 psi) 5 hp

1500HDX-D14, V12f 9.05 Lpm (2.39 gpm) 21 bar (300 psi) 214 bar (3100 psi) 10 hp




Servo manifold assemblyA standard servo manifold (3, Figure 19) includes the following components. Refer to Table 5 for the function of each component.

• A servo valve

• An oil filter

• A system pressure gauge

• A dump valve

• An idle pressure valve

• A system relief valve

Crosshead motor manifoldThe crosshead motor manifold is located on the rear of the adjustable crosshead. The manifold routes oil to the motor for the adjustable crosshead. A three-position valve in the manifold provides control of the oil flow from the manifold to the motor. The three-position valve is controlled by the operator through the crosshead up/down switch on the front of the adjustable crosshead.

Table 5. Function of components on servo manifold.

Component Function

Servo valve: The servo valve controls the flow of oil to the hydraulic cylinder. The position of the servo valve, which is determined by parameters entered into the controlling software by the operator, defines how the hydraulic cylinder will operate. It will either block the flow of oil to the hydraulic cylinder to hold the piston stationary, allow oil to enter the hydraulic cylinder to extend the piston, or allow oil to return to the reservoir to retract the piston.

Oil filter: A high pressure 3-micron oil filter is mounted on the manifold to provide the necessary filtration for the high performance hydraulic components in the system. Oil passes through this filter directly after exiting the pump and before being routed to any other hydraulic component. The filter is equipped with an indicator to show when the filter is dirty and should be serviced. For maintenance of the oil filter, refer to maintenance information provided in the System Operating Instructions (supplied separately).

System pressure gauge:

A pressure gauge is located on the servo manifold so that system pressure can be monitored as needed. This pressure gauge is visible through a cut out in the rear cover of the console. System pressure is set at the factory and should not require further adjustment. Any adjustments should only be made by an Instron service engineer.

Dump valve: When unloading the frame, the servo valve changes position to allow oil to return through the system to the reservoir. Also, the dump valve can open to allow oil to return directly to the reservoir, thus providing for a faster unload rate. The dump valve actually cycles to maintain the error signal within prescribed limits. This can cause a pulsing sound from the frame while it is unloading. This is considered normal and is not a cause for concern.

Idle pressure valve: The idle pressure valve controls the pressure of the HPS when it is operating under no load conditions (i.e. when the frame is not being adjusted or performing a test). This valve is set at the factory and should not require further adjustment. Any adjustments should only be made by an Instron service engineer.

System relief valve: The system relief valve provides pressure relief for the system to prevent damage to system components in the event that the pump builds too much pressure. This valve is set at the factory and should not require further adjustment. Any adjustments should only be made by an Instron service engineer.

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Frame manifoldThe frame manifold is located in the base of the frame and is visible through a cut out in the rear of the base (see Figure 2 on page 16). The frame manifold provides routing of the hydraulic oil from the servo manifold on the HPS to the various hydraulic components on the frame:

• Hydraulic cylinder - Main pressure from the servo manifold enters the frame manifold and then exits to the pressure connection on the cylinder body.

• Adjustable crosshead motor - Auxiliary pressure from the servo manifold enters the frame manifold and is routed for operation of the adjustable crosshead motor. As the oil passes through the frame manifold, a pressure reducing valve reduces the pressure of the oil to the pressure needed by the crosshead motor. A pressure gauge is provided so that oil pressure can be monitored as needed. The pressure reducing valve is set at the factory and should not require further adjustment. Any adjustments should only be made by an Instron service engineer. Oil exits the frame manifold and is routed to the crosshead motor manifold on the rear of the adjustable crosshead.

• Grip assemblies - For frames with G7-style crossheads, auxiliary pressure from the servo manifold enters the frame manifold and is routed to the hydraulic grips manifold that is mounted next to the frame manifold (see Figure 2 on page 16).

Hydraulic grips manifoldFor frames equipped with G7-style crossheads, a hydraulic grips manifold is provided. The hydraulic grips manifold is located on the rear of the frame base (see Figure 2 on page 16). As the oil passes through the hydraulic grips manifold, a pressure reducing valve reduces the pressure of the oil to the pressure needed by the grip assemblies. The pressure reducing valve is set at the factory and should not require further adjustment. Any adjustments should only be made by an Instron service engineer. Oil exits the hydraulic grips manifold and is routed to the speed control manifold on the rear of each crosshead.

Speed control manifoldsFor frames equipped with G7-style crossheads, two speed control manifolds are provided for the in-head grip assemblies. A speed control manifold is located on the rear of each crosshead. Each manifold includes two flow control valves that control the opening and closing speed of the grip jaws in the hydraulic grip assemblies (see “Clamping Speed” on page 35).

Pressure settingsAll relief valves, reducing valves, pressure switches, etc. are set at the factory to their proper operating pressure. They should not need further adjustment. If you feel adjustment is necessary, contact your local Instron Services department as directed on page 13. Any adjustments should only be made by an Instron service engineer.

Oil coolingAn air-over-oil heat exchanger and fan (1, Figure 19) are used to cool the oil and exhaust the warm air from the console. The fan is mounted to the rear cover and has a guarded vent hole. Fresh air is drawn into the console through a guarded vent hole on the side of the console. This vent hole is equipped with a filter.




TroubleshootingIn the event that problems arise during operation of the system, refer to Table 6 for help in determining the specific problem and its solution. If the problem cannot be determined through the chart, contact your local Instron Services department as directed on page 13. Another option would be to check the listing of Frequently Asked Questions (FAQs), available on the Instron website (www.instron.com), for a description/solution to your problem.

Table 6. Troubleshooting the HDX system.

No. Possible Indications Possible Problem Solution

1

• The indicators on the SERVICE display do not light when the system disconnect switch is turned on

• Frame power is lost for no apparent reason

• Test aborts and HPS shuts down• Frame will not enable• An interlock error message appears

in the controlling software

Frame and/or 59 Series control unit are not receiving power

• Check incoming power supply for both frame and control unit

A fuse could be blown • Check all system fuses, refer to “Replacement of fuses” on page 54.

2

• HPS will not start Always verify that:

• Computer is on• 59 Series control unit is on• Controlling software is running• Frame is enabled• A test procedure/method is open• The load transducer is calibrated

Emergency Stop engaged Disengage Emergency Stop button, enable frame and start HPS

System disconnect switch not ON ( | )

Turn the disconnect switch to ON ( | ).

Overload protect circuit may have tripped

For assistance, contact your local Instron Services department as directed on page 13

Limit switch tripped Check limits and adjust frame as necessary to reset the limit, then enable the frame and start the HPS

If none of the above appear to be the problem:

• For Partner systems, check the Status display for any abnormal conditions or check the On-line Help for other helpful information

• For Bluehill systems, check the Status Log for any abnormal conditions. Click the Load Frame icon; the Status Log appears on the bottom portion of the Load Frame tab.

46 M47-17032-EN

Frame

3

• System locks up• Test will not start• Test aborts• Software posts an error message

stating that communication is lost• Transducers will not calibrate• Flashing single point LED on

diagnostic display is not present

Communication between frame and controls is lost.

Reset the system by performing the shutdown and startup procedures that are provided in the System Operating Instructions (supplied separately).

4

• Test will not start• Test aborts• HPS shuts down• Software posts an error message

stating “Position Loop Failure”

Position measurement is not working

Check the position encoder cable for damage or loose connection. If problem is not resolved, refer to Problem No. 12

Piston is sitting at the bottom of the cylinder

Enable the frame, start the HPS and move the piston (loading unit) up approximately 6 mm (0.25 in), zero all measurements, and calibrate all transducers

5

• Software posts an error message stating “Control Panel Watchdog Timeout”

Communication has been lost with the user control panel

Check the user control panel cable for damage. If damage is found contact your local Instron Services department as directed on page 13.

6

• After opening a procedure the HPS will not start

The frame is not enabled Enable the frame:

• For Partner systems, select Machine and then Enable Frame

• For Bluehill systems, select the Frame icon and then Enable Frame

For systems operating with Partner software, the “Enable Frame Timer” setting may be enabled

Verify the status of the “Enable Frame Timer” check box in Partner:

1. Select Tools/Configure/Controllers; Controller window will open.

2. Select the controller (59-R8) and click Modify.

3. Be sure the “Enable Frame Timer” box is NOT checked.

7

• For Partner systems: after starting a procedure, the live data and live graph appear on the computer monitor but the frame is not moving

The software could be in Simulation mode

Verify that the lower right corner of the screen does not have the word “SIM”. If it does, select Tools/Configure/Simulation and uncheck the “Simulate Test” box

Table 6. Troubleshooting the HDX system. (Continued)





8

• During a tensile test, the load reading stays steady or jerks up or down (instead of moving at a consistent rate) while position increases

• Motion is visible between the specimen and a crosshead (i.e. specimen stays still while crosshead is moving or vice versa)

The specimen is slipping in the grip jaws, possibly due to:

• Specimen not seated properly

• Unload the specimen and reclamp the grip jaws on the specimen

• Incorrect grip jaw type for the specimen being tested

• Determine the best grip jaw type for your specimen (refer to information provided in the System Operating Instructions (supplied separately))

• Damaged grip jaws • Inspect the grip jaws (refer to maintenance information provided in the System Operating Instructions (supplied separately))

• Improperly lubricated grip components

• Check lubrication of grip components (refer to maintenance information provided in the System Operating Instructions (supplied separately))

• Insufficient initial clamping force

• For frames with G1-style crossheads: Use additional force to clamp the grip jaws on the specimen, but DO NOT hammer grip components.

• For frames with G7-style crossheads: Watch the pressure gauge on the grips manifold while clamping the specimen, it should read approximately 20.7 bar (300 psi). If it does not, or if this seems insufficient for your testing needs, contact your local Instron Services department as directed on page 13.

9

• During a tensile test when an extensometer is being used, no elongation is measured

The specimen is slipping in the grip jaws

See Problem No. 8.

The extensometer cable could be damaged or have loose connections

Check the extensometer cable for damage and check that connections are secure. If damage is found contact your local Instron Services department as directed on page 13.

10

• During a tensile test, a clicking sound comes from the grip jaws

• During a tensile test, a bump appears in the graph

• Galling or scuffing of the grip jaws or grip pocket is observed

• Bending, tearing, or scarifying of the wear plates (see example shown in Chapter 4 of the System Operating Instructions (supplied separately).

The grip jaws are improperly lubricated

Unload the specimen and remove it from the grips. Relubricate grips as outlined in the System Operating Instructions (supplied separately). Assemble grip components and install specimen in grip jaws.



48 M47-17032-EN

Frame

11

• Software posts an error message stating “Sensor Loop Failure”

Control rate for the control mode selected is too fast

The frame should not be operated in load/stress control during the yield portion of a test. Select position or strain control and restart test, or contact your local Instron Services department as directed on page 13.

Load cell cable could be damaged or have loose connections

Check load cell cable for damage and check that connections are secure

12

• Position display does not change when the hydraulic cylinder is moving

• The hydraulic cylinder stops inadvertently during a test or during manual adjustment

• Software indicates a “Hard Stop” or other error for no apparent reason

Disconnect switch not ON ( | ) or customer’s power supply not ON

• Turn the disconnect switch to ON• Turn the customer’s power supply to

ON

Set speed exceeds the load frame maximum speed

Reduce the set speed and enable frame

Position encoder not functioning or damaged

Check operation of position encoder:

1. Enable the frame.2. Start the HPS.3. Manually jog the hydraulic cylinder,

verify that it is moving and watch the position display to see if it reads the change in height.

4. If after 3 seconds the HPS shuts down, then the encoder is not functioning; contact your local Instron Services department as directed on page 13.

13

• Software indicates a “Hard Stop” or other error when running a test under strain control

Strain instrument may not be working properly

• Check the instrument for proper operation

• Check that the zero pin was removed from the instrument






14

• Adjustable crosshead has been jammed into the table and will not move. It is possible to overload the crosshead motor. If it is overloaded, oil is relieved back to the reservoir. Damage to load cell, fixtures, etc. could result.

If a specimen is gripped or the indicated load is more than 1% of frame capacity, contact your local Instron Services department as directed on page 13.

If there is no specimen gripped and indicated load is less than 1% of frame capacity:

1. Turn the system disconnect switch to OFF ( O ).

2. Watch movement of the compression table. If the compression table moves away from the crosshead as the piston falls, continue with next step. If the compression table does not move away from the crosshead as the piston falls, contact your local Instron Services department as directed on page 13.

3. Inspect the frame and any installed fixtures for obvious damage.

4. Spot check load accuracy of the system, contact your local Instron Services department as directed on page 13.

15

• The HPS shuts down• Software posts a motor temperature

error message

Oil level has dropped below the allowable level

Perform checks and/or corrections for an oil leak and then add oil to the reservoir. Refer to procedures provided in Chapter 4 of the System Operating Instructions (supplied separately).

Oil temperature exceeds temperature switch setpoint, possibly due to:

• Fans not operating properly • Check for and correct fan operation

• Environmental conditions exceed requirements provided in Chapter 2 of the System Operating Instructions (supplied separately)

• Correct environmental conditions

Oil temperature must drop below the maximum temperature stated in “Oil temperature/level switch” on page 43 to reset the switch. Once the switch has reset, the HPS can be started.

16• Pump Start button is lit but HPS is

not runningThe disconnect switch not ON ( | ) or customer’s power supply not ON

• Turn the disconnect switch to ON ( | )• Turn the customer’s power supply to

ON



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17

• The software posts an error message like the one shown in Figure 20

• EFI cable could be damaged or have loose connections

• Communication problem between EFI and 59 Series control unit or EFI and software

• Incorrect version of controlling software is in use

• Check the cable for damage and check that connections are secure

• Check that the correct Ethernet crossover cable is being used

• Check IP settings, they should match those shown in Figure 21

• Verify that the software version is 8.2a or above for Partner, or 2.15 or above for Bluehill

• If none of the above correct the problem, then contact your local Instron Services department as directed on page 13



Figure 20. Controlling software error messages.

Partner Software

Bluehill Software




Figure 21. Internet protocol properties.

52 M47-17032-EN

Chapter 4Parts Replacement

• Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

• Replacement of fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

• Replacement or repair of load cells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

IntroductionHDX systems require minimal parts replacement. If a part does require replacement, only the following parts can or should be replaced by the customer:

• Fuses

All other parts replacement should be done by an Instron service engineer. For assistance with replacement of any part, contact your local Instron Services department as directed on page 13.

53

Chapter 4: Parts Replacement

Replacement of fusesThe system is equipped with fuses as outlined in Table 7.

These fuses should only need replaced when they are blown. Problems that indicate a blown fuse are described in Table 6 on page 46; refer to Problem No. 1. If you believe a fuse could be blown, perform the following check to pinpoint which fuse is blown:

1. Start up the system according to the system startup procedure provided in the System Operating Instructions (supplied separately).

2. Check the indicators on the SERVICE display of the 59 Series control unit (see page 39), they should be lit. If the indicators are not lit, then the power entry module fuses could be blown. Visually inspect the fuse. Follow the procedure outlined under “Inspect/replace 59 Series power entry module fuses” on page 55 to access and locate the fuse. If the fuse is blown, replace it. Information for the fuse can be found in Table 7.

Table 7. Fuse information.

Fuse Description SpecificationsInstron

Part Number Quantity

Fuses in power entry module of 59 Series control unit

5 amp, 1/4D x 1-1/4LG, 250Vac(equivalent metric size is 6.3D x 32LG)

300-8905-9159 2

54 M47-17032-EN

Replacement or repair of load cells

Inspect/replace 59 Series power entry module fusesThe 59 Series power entry module fuses are located in the power entry module on the rear of the 59 Series control unit. Perform the following procedure to inspect or replace the fuses.

Equipment requiredNo equipment is required, although it may be helpful to have a flat screwdriver to remove the fuse holder.

Recommended procedure1. Be sure the system is shut down. All power should be off.

2. Depress the tab of the fuse holder (see Figure 22) and remove it from the power entry module.

3. Inspect or change fuses as necessary. Fuse specifications are listed in Table 7.

4. Once work is complete, replace the fuse holder.

Replacement or repair of load cellsInstron load cells, in general, are electrically calibrated, self-identifying and rationalized. Approximate resistances can be provided to allow confirmation of a possible broken gauge, or a faulty connector or cable.

If a strain gauge in a cell has been badly overstressed, but still maintains its electrical continuity, the cell may show a higher than normal amount of creep. If a gauge has become improperly bonded due to degradation in use, the cell may exhibit a combination of general instability in its balance point, together with a large amount of creep. Difficulties of this sort rarely appear as an instability in the calibration of the cell.

If a load cell has been overloaded, the load-sensitive member may be permanently deformed to the extent that the proper dimensional alignments inside the cell are no longer maintained. If you suspect that a cell may be damaged, contact your local Instron Services department as directed on page 13 to arrange returning the load cell for analysis and possible repair.

Figure 22. 59 Series power entry module fuses.

Power entry module

Fuse holder



Chapter 4: Parts Replacement

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56 M47-17032-EN

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